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CAP-215

29

Instruction Manual Oil-Less Compressors

11. REPAIR

INSTRUCTIONS

11.1. GENERAL

Preventive maintenance usually involves replacing the gaskets and sealing rings as well as carrying out the

maintenance

work.

Repair work can be carried out on the oil-less compressor to a certain extent, however certain repair work

requires

experience and skill. Furthermore please note that:

- repair work on crankshaft and bearing support should always be carried out by a skilled person, - safety valves

are not repaired but always replaced completely.

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Содержание OL 512

Страница 1: ...3 H P OL 512 SINGLE STAGE 5 H P OL 524 TWO STAGE 5 H P OL 812 SINGLE STAGE 7 1 2 H P OL 812 SINGLE STAGE 10 H P CAUTION Before installing this compressor read and understand the safety precautions co...

Страница 2: ...ESCRIPTION 13 2 2 INTAKE FILTER MAINTENANCE 13 3 INTERMEDIATE AND FINAL SEPARATOR 14 3 1 FUNCTIONAL DESCRIPTION OF INTERMEDIATE SEPARATOR 2 STAGE COMPRESSSOR ONLY 14 3 1 1 CONDENSATE DRAIN 14 3 1 2 IN...

Страница 3: ...UCTIONS 29 11 1 GENERAL 29 12 TROUBLE SHOOTING 30 13 TABLES 31 13 1 TIGHTENING TORQUE VALUES 31 13 2 TORQUE SEQUENCE 31 13 3 MAINTENANCE SCHEDULE 32 33 TABLE OF FIGURES Fig 1 OL 512 REAR VIEW 2 Fig 2...

Страница 4: ...MENSIONS 070308 1015 33 Fig 20 1 STAGE COMPRESSOR DIMENSIONS 070307 1015 35 Fig 21 1 STAGE COMPRESSOR DIMENSIONS 077734 36 Fig 22 Fig 23 D51 2 DIAGRAM SPARE PARTS LIST OF CYLINDER PISTON INTAKE VALVE...

Страница 5: ...UCTIONS SHOULD BE OBSERVED AND CARRIED OUT IN THE ORDER LAID DOWN TO PREVENT DAMAGE AND PREMATURE WEAR TO THE EQUIPMENT AND THE COMPRESSORS SERVED BY IT WHILE EVERY EFFORT IS MADE TO ENSURE THE ACCURA...

Страница 6: ...nit manufactured by Curtis Toledo Inc is hereby warned that failure to observe all safety precautions may result in serious injury to personnel and or damage to property Curtis Toledo Inc neither stat...

Страница 7: ...relief valve restrict the function of the pressure relief valve or replace the pressure relief valve with a plug Do not install a shutoff valve in the compressor discharge line without first Installi...

Страница 8: ...fore it is extremely important that you examine every carton and crate as soon as you receive it If there is any obvious damage to the shipping container have the delivering carrier sign the freight b...

Страница 9: ...lly unloaded upon starting and will automatically load after attaining running speed If the compressor is equipped with a constant speed control pilot valve unloading it is necessary to manually unloa...

Страница 10: ...ng 104 F water or extremely dirty air could be ingested These types of atmospheres could adversely affect the performance of the compressor system COMPRESSED AIR DISCHARGE SYSTEM Typical Drop Leg Comp...

Страница 11: ...a compressor from a pressurized tank or compressed air delivery system during maintenance procedures MANUAL SHUTOFF VALVES Manual shutoff valves block the flow of air pressure in either direction This...

Страница 12: ...k on just because It Is not operating It could start at any time 1 Per O S H A regulation 1910 147 The Control of Hazardous Energy Source Lockout Tagout disconnect and lockout the main power source Di...

Страница 13: ...length of the drive Refer to MAINTENANCE SCHEDULE See instructions in the respective model manual 2 Determine the amount of deflection in inches required to measure deflection force in pounds by multi...

Страница 14: ...ollowing construction characteristics friction treated surface of the cylinders PTFE polytetrafluoride ethylene compound coated piston guiding surfaces piston rings made exclusively from special PTFE...

Страница 15: ...Less Compressors Fig 1 OL 512 single stage rear view 1 Cooler Manifold 2 After cooler 3 Cylinder 1st stage 4 Valve head 1st stage 5 Fan flywheel 6 Final Separator optional 7 Intake filter 8 Condensate...

Страница 16: ...CAP 215 Instruction Manual Oil Less Compressors Fig 2 OL 512 single stage left side view 1 Cooler Manifold 2 After cooler 3 Final Separator optional 4 Intake filter 5 Valve Head 6 Fan flywheel 3...

Страница 17: ...Safety valve 1st stage 3 Intermediate cooler 4 Manifold 2nd stage 5 Cylinder 1st stage 6 Valve head 1st stage 7 Intermediate separator 8 Fan flywheel 9 Intermediate cooler 10 Manifold 1st stage 11 Fi...

Страница 18: ...mpressors Fig 4 OL 524 2 stage left side view 1 Final separator 2 Manifold 3 After cooler 4 Intermediate separator option 5 Intake filter 6 Valve head 2nd stage 7 Cylinder 2nd stage 8 Fan flywheel 9 C...

Страница 19: ...al Oil Less Compressors Fig 5 OL 812 single stage rear view 1 Cylinder 1st stage 2 After cooler 3 Intake filter a position of automatic condensate drain optional 4 Ventilator flywheel 5 Final separato...

Страница 20: ...CAP 215 7 Instruction Manual Oil Less Compressors Fig 6 OL 812 single stage left side view 1 Cooler manifold 2 After cooler 3 Final separator...

Страница 21: ...or The positions stated refer to Fig 1 The outside air is drawn in through the three first stages 3 of the oil less compressor via intake filter crankcase and piston and compressed to a final pressure...

Страница 22: ...nifold is adjusted to a pressure of 120 psi The condensate is filtered out in the intermediate separator 7 and is lead to the condensate drain valve 15 option The 2nd stage compresses the air now to a...

Страница 23: ...very Operating pressure max No of cylinders Cylinder bore 1st stage Cylinder bore 2nd stage Adjustment of intermediate pressure safety valve Piston stroke Speed Weight Drive input e Compressor rotatio...

Страница 24: ...y Operating pressure max No of cylinders Cylinder bore Piston stroke Speed Weight Drive input g Compressor rotation Min max ambient temperature OL 812 1 48 cfm atmospherical 31 6 cfm at 110 psi 110 ps...

Страница 25: ...UKI 2 5 V PTC resistance temperature NAT T PTC resistance UKI 2 5 V at PTC resistance temperature NAT T PTC resistance UKI 7 5 V at PTC resistance temperature NAT 15 C Isolation strength Uis Operating...

Страница 26: ...indicate contamination of the filter cartridge and the necessity to clean or change it The maintenance indicator reacts at a vacuum of 1 5 in Hg Fig 10 Intake filter 1 Wing nut 2 Filter housing 3 Filt...

Страница 27: ...nted on the lower part of separator housing After draining the condensate firmly tighten knurled nut Compressors which are equipped with a condensate drain valve are drained automatically Ensure that...

Страница 28: ...housing After draining the condensate firmly tighten knurled nut Compressors equipped with a condensate drain valve are drained automatically Ensure that the filters are drained every 15 minutes At i...

Страница 29: ...suction stroke the intake valves open and the air flows into the cylinders At the start of the compression stroke the intake valve closes and the air opens the pressure valve see Fig 10 Fig 12 Valve o...

Страница 30: ...nts for excessive wear If the valve seat and valve disks are dented replace the valves Valve head screws must be tightened with a torque wrench see tightening torque values chapter 13 Check the valve...

Страница 31: ...cooler Remove counter sunk screw 1 together with fixation nut 2 from piston head Remove plate valve 3 Fig 14 valve head 1st stage 4 6 CHANGING 2ND STAGE VALVES AND VALVES OF 1ST STAGE PRESSURE VALVE...

Страница 32: ...operation stand still drainage A solenoid valve is installed as a condensate drain valve which is open when it does not receive any power It works electro pneumatically 5 2 FUNCTION The solenoid valve...

Страница 33: ...ough the flywheel cover from the surroundings and thus cools the cylinder both intercoolers and the after cooler The fan blades are mounted on the flywheel and are powered by the driving motor Additio...

Страница 34: ...CAP 215 21 Instruction Manual Oil Less Compressors 7 SAFETY REGULATIONS 7 1 GENERAL...

Страница 35: ...CAP 215 22 Instruction Manual Oil Less Compressors...

Страница 36: ...anner that the compressor fan can get fresh air from outside for instance through an opening in the wall Ensure that an adequate exhaust air opening is provided see Fig 16 When locating the compressor...

Страница 37: ...ntake side 1 6405 ft B Minimum distance from wall exhaust air side 2 46075 ft The opening for intake air A2 should be approx 20 larger than the opening for exhaust air A3 taking into account louvers g...

Страница 38: ...ich delivers 1177 cfm against 100 pa resistance Cooling air fan p and V1 Fig 17 Installation with forced ventilation A Minimum distance from wall intake side 1 6405 ft B Minimum distance from wall exh...

Страница 39: ...on observing the following points Prior to first operation read lnstruction Manual carefully Make sure that all persons handling the compressor and the filling station are familiar with the function o...

Страница 40: ...Check plate valves replace if necessary Check conrod bearing and piston pin bearing replace if necessary 20 000 operating hours Check driving gear main bearing replace if necessary at least every 3 y...

Страница 41: ...approx 10 minutes Then carry out the following Check all pipes filters and valves also safety valves for leakage Tighten all couplings as required Continue to run compressor for another 5 minutes at a...

Страница 42: ...as well as carrying out the maintenance work Repair work can be carried out on the oil less compressor to a certain extent however certain repair work requires experience and skill Furthermore please...

Страница 43: ...outlet valves not closing Check and clean valves replace properly as necessary Wrong direction of rotation See arrow on compressor and remedy accordingly Control does not switch off Final pressure swi...

Страница 44: ...lf retaining nuts on reassembly 13 2 TORQUE SEQUENCE Tighten valve head and cylinder bolts nuts equally in the sequence shown in Fig 16 Be sure to tighten all parts in cold condition only Figure 18 To...

Страница 45: ...heel drive changed V belt compressor drive checked V belt compressor drive adjusted V belt compressor drive changed Filter cartridge and inter mediate separator cleaned Filter cartridge filter set cha...

Страница 46: ...belt fan wheel drive changed V belt compressor drive checked V belt compressor drive adjusted V belt compressor drive changed Filter cartridge and inter mediate separator cleaned Filter cartridge fil...

Страница 47: ...CAP 215 Fig 19 2 stage compressor dimensions 070308 1015 34...

Страница 48: ...CAP 215 35 Fig 20 1 stage compressor dimensions 070307 1015...

Страница 49: ...CAP 215 36 Fig 21 1 stage compressor dimensions 077734...

Страница 50: ...bly 3 9 3 CCC1466 Intake valve assembly 4 CCC1619 Countersunk screw 5 CCC1555 Fixation nut 6 CCC1554 Reed valve 7 CCC1634 Cylinder pin 2m 6 x 4 lg DIN 7 3 9 8 CCC1468 Piston ring 85 9 CCC1565 Circlip...

Страница 51: ...bly 2 6 3 CCC1466 Intake valve assembly 4 CCC1619 Countersunk screw 5 CCC1555 Fixation nut 6 CCC1554 Reed valve 7 CCC1634 Cylinder pin 2m 6 x 4 lg DIN 7 2 4 8 CCC1468 Piston ring 85 9 CCC1565 Circlip...

Страница 52: ...CURTIS TOLEDO INC 1905 KIENLEN AVE ST LOUIS MO 63133 TEL 314 383 1300 FAX 314 381 1439 E MAIL CURTISCOMP AOL COM...

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